Specimen creating device

ABSTRACT

An object is to provide an inspection sample making apparatus ( 30 ) that can simplify work for making an inspection sample ( 12 ) and can ensure inspection for seal condition. The inspection sample making apparatus ( 30 ) includes a preliminary-inspection-sample-making device ( 20 ) for peeling a predetermined fusion-bonded piece of a packaging container ( 10 ) off a wall of the packaging container ( 10 ) so as to make a preliminary inspection sample ( 20 ); and a cutting device for cutting the preliminary inspection sample ( 52 ) along a predetermined cutting line so as to make an inspection sample ( 12 ). Since the preliminary-inspection-sample-making device ( 20 ) peels a predetermined fusion-bonded piece of the packaging container ( 10 ) off a wall of the packaging container ( 10 ) to thereby make the preliminary inspection sample ( 52 ), and the cutting device cuts the preliminary inspection sample ( 52 ) along a predetermined cutting line to thereby make the inspection sample ( 12 ), an operator does not need to manually make the inspection sample ( 12 ). Therefore, not only is work for making the inspection sample ( 12 ) simplified, but also cutting at a wrong position is avoided. As a result, a seal condition inspection apparatus ( 31 ) can reliably inspect seal condition.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Phase Application (35 USC 371) ofPCTIJP2003/012960 and claims priority of Japanese Application No.2002-307050 filed Oct. 22, 2002.

TECHNICAL FIELD

The present invention relates to an inspection sample making apparatus.

BACKGROUND ART

Conventionally, in production of packaging containers that containliquid food such as milk or soft drink, a web-like packaging material, asheet-like packaging material, or the like is formed into packagingcontainers by means of sealing at predetermined positions through heatsealing, ultrasonic sealing, or a like method. For example, in the caseof using a web-like packaging material, the web-like packaging materialis formed into a tubular shape; the tubular packaging material is sealedin the longitudinal direction by means of a longitudinal sealing device,which serves as a first sealing device; while being filled with liquidfood, the longitudinally sealed tubular packaging material is sealed inthe lateral direction and cut at predetermined intervals by means of alateral sealing device, which serves as a second sealing device, tothereby yield a pillow-like prototype container; and the prototypecontainer is formed into a final packaging container.

Meanwhile, in order to seal the above-mentioned packaging material, thepackaging material is gripped from opposite sides with a predeterminedgripping force, and resin on the surfaces of the packaging material ismelted through application of heat, thereby fusing together the surfacesof the packaging material. However, for example, under a certaincondition, such as a certain gripping force, a certain sealingtemperature, or a certain resin property, molten resin escapes from aseal portion. As a result, the amount of resin remaining in the sealportion becomes insufficient, potentially resulting in occurrence of aseal defect. Occurrence of a seal defect involves leakage of liquid foodfrom a packaging container or entry of air into the packaging container,with a resultant deterioration in the quality of liquid food.

Thus, in accordance with an inspection manual, an operator inspects aseal portion for seal condition. Specifically, the operator samplescompleted packaging containers in accordance with the manual; emptiesthe sampled packaging containers of liquid food; cuts the emptypackaging containers open by use of a cutter or the like; cleans anddries the opened packaging containers to thereby make inspectionsamples; and visually inspects seal portions for seal condition from theinside of each of the inspection samples.

However, the above-mentioned conventional method for making aninspection sample requires an operator to manually make an inspectionsample, thus involving troublesome work. Also, if the operator cuts thesampled packaging container at a wrong position, inspection for sealcondition will become unreliable.

An object of the present invention is to solve the above-mentionedproblem in the conventional method for making an inspection sample andto provide an inspection sample making apparatus that can simplify workfor making an inspection sample and can ensure inspection for sealcondition.

DISCLOSURE OF THE INVENTION

To achieve the above object, an inspection sample making apparatus ofthe present invention comprises a preliminary-inspection-sample-makingdevice for peeling a predetermined fusion-bonded piece of a packagingcontainer off a wall of the packaging container so as to make apreliminary inspection sample; and a cutting device for cutting thepreliminary inspection sample along a predetermined cutting line so asto make an inspection sample.

In this case, the preliminary-inspection-sample-making device peels apredetermined fusion-bonded piece of a packaging container off a wall ofthe packaging container, thereby making a preliminary inspection sample.The cutting device cuts the preliminary inspection sample along apredetermined cutting line, thereby making an inspection sample. Thus,an operator does not need to manually make an inspection sample.Therefore, not only is work for making an inspection sample simplified,but also cutting at a wrong position is avoided. As a result, a sealcondition inspection apparatus can reliably inspect seal condition.

In another inspection sample making apparatus of the present invention,the preliminary-inspection-sample-making device comprises a drivesection and a peeling piece, which is rotated through activation of thedrive section.

The peeling piece comprises an insert portion to be inserted between thefusion-bonded piece and the wall.

In still another inspection sample making apparatus of the presentinvention, the peeling piece is formed of a thin plate.

In yet another inspection sample making apparatus of the presentinvention, the cutting device comprises a first cutting device forcutting the preliminary inspection sample along a laterallypredetermined first cutting line, and a second cutting device forcutting the preliminary inspection sample along longitudinallypredetermined second and third cutting lines.

In a further inspection sample making apparatus of the presentinvention, the first cutting device comprises a cutting tool.

In a still further inspection sample making apparatus of the presentinvention, the second cutting device comprises first and second blades.

A still further inspection sample making apparatus of the presentinvention further comprises a cleaning device for cleaning thepreliminary inspection sample.

In a still further inspection sample making apparatus of the presentinvention, the cleaning device comprises a press member for ejecting aliquid food from the inside of the preliminary inspection sample.

A still further inspection sample making apparatus of the presentinvention further comprises a drying device for drying the inspectionsample.

A still further inspection sample making apparatus of the presentinvention further comprises an opening mechanism for opening theinspection sample. The drying device dries the inspection sample in anopened condition.

In a still further inspection sample making apparatus of the presentinvention, the inspection sample comprises at least two plate-likeportions which are fusion-bonded together at a fusion bond portion.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view of a prototype container associated with anembodiment of the present invention;

FIG. 2 is a perspective view of a packaging container associated withthe embodiment of the present invention;

FIG. 3 is a perspective view showing a method for making an inspectionsample according to the embodiment of the present invention;

FIG. 4 is a first perspective view showing apreliminary-inspection-sample-making step according to the embodiment ofthe present invention;

FIG. 5 is a second perspective view showing thepreliminary-inspection-sample-making step according to the embodiment ofthe present invention;

FIG. 6 is a perspective view of a preliminary inspection sampleassociated with the embodiment of the present invention;

FIG. 7 is a plan view showing a first cutting step according to theembodiment of the present invention;

FIG. 8 is a front view showing the first cutting step according to theembodiment of the present invention;

FIG. 9 is a front view showing a cleaning step according to theembodiment of the present invention;

FIG. 10 is a plan view showing the preliminary inspection sampleassociated with the embodiment of the present invention as viewed afterthe first cutting step and the cleaning step;

FIG. 11 is a plan view showing the relationship between the preliminaryinspection sample and a cutting device according to the embodiment ofthe present invention;

FIG. 12 is a front view showing the relationship between the preliminaryinspection sample and the cutting device according to the embodiment ofthe present invention;

FIG. 13 is a first front view showing a second cutting step according tothe embodiment of the present invention;

FIG. 14 is a second front view showing the second cutting step accordingto the embodiment of the present invention;

FIG. 15 is a perspective view showing an inspection sample associatedwith the embodiment of the present invention; and

FIG. 16 is a front view showing a drying step according to theembodiment of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

An embodiment of the present invention will next be described in detailwith reference to the drawings.

FIG. 1 is a front view of a prototype container associated with theembodiment of the present invention, and FIG. 2 is a perspective view ofa packaging container associated with the embodiment of the presentinvention.

In FIGS. 1 and 2, reference numeral 10 denotes a packaging container,and reference numeral 18 denotes a prototype container. The packagingcontainer 10 includes a front wall 10 a; a back wall 10 b; side walls 10c and 10 d; a top wall 10 e; a bottom wall 10 f; a pair of top flaps 10g (FIG. 2 shows only a single top flap 10 g), the pair being bent ontothe side walls 10 c and 10 d from the top wall 10 e and serving as afirst fusion-bonded piece or a first lug; and an unillustrated pair ofbottom flaps, the pair being bent from the side walls 10 c and 10 d ontothe bottom wall 10 f and serving as a second fusion-bonded piece or asecond lug. The top flaps 10 g are fusion-bonded to the correspondingside walls 10 c and 10 d by melting resin. Similarly, the bottom flapsare fusion-bonded to the bottom wall 10 f by melting resin.

In this case, a longitudinal seal portion S1 is formed in such a manneras to extend on the top wall 10 e, the back wall 10 b, and the bottomwall 10 f. A lateral seal portion S2 associated with the top wall 10 eis formed in such a manner as to extend on the top wall 10 e and the topflaps 10 g, and a lateral seal portion S2 associated with the bottomwall 10 f is formed in such a manner as to extend on the bottom wall 10f and the bottom flaps.

The packaging container 10 is formed, for example, through a fillingapparatus working on a web-like packaging material.

Specifically, a web-like packaging material is set on a delivery unit ofthe filling apparatus; is delivered by means of the delivery unit; andis caused to travel through the filling apparatus by means of a feedunit. While the packaging material is traveling, a hole is punched inthe packaging material, and an inner tape and a pull tab are affixed tothe packaging material in such a manner as to cover the punched hole.Subsequently, the packaging material is caused to travel vertically.While being guided by a plurality of forming rings disposed along thetraveling direction, the vertically traveling packaging material isformed into a tubular shape. The tubular packaging material is sealed inthe longitudinal direction by means of a longitudinal sealing device. Inthis manner, the longitudinal seal portion S1 is formed.

Subsequently, liquid food is supplied from above into thepackaging-material tube via a filling pipe. Next, a lateral sealingdevice grips the packaging-material tube from opposite sides, and thepackaging-material tube is laterally sealed at predeterminedlongitudinal intervals, thereby forming lateral seal portions S2. Thepackaging-material tube is cut at the lateral seal portions S2 and isformed into the pillow-like prototype container 18 through deformationeffected by forming flaps.

Meanwhile, in order to seal the above-mentioned packaging material, thepackaging material is gripped from opposite sides with a predeterminedgripping force, and resin on the surfaces of the packaging material ismelted through application of heat, thereby fusing together the surfacesof the packaging material. However, for example, under a certaincondition, such as a certain gripping force, a certain sealingtemperature, or a certain resin property, molten resin escapes from aseal portion, such as the longitudinal seal portion S1 or the lateralseal portion S2. As a result, the amount of resin remaining in the sealportion becomes insufficient, potentially resulting in occurrence of aseal defect. Occurrence of a seal defect involves leakage of liquid foodfrom the packaging container 10 or entry of air into the packagingcontainer 10, with a resultant deterioration in the quality of liquidfood.

Thus, the completed packaging containers 10 undergo predeterminedsampling. The sampled packaging containers 10 are cut open to therebybecome inspection samples. The inspection samples are inspected for sealcondition at seal portions.

Next, an apparatus and a method for making an inspection sample will bedescribed.

FIG. 3 is a perspective view showing a method for making an inspectionsample according to the embodiment of the present invention; FIG. 4 is afirst perspective view showing a preliminary-inspection-sample-makingstep according to the embodiment of the present invention; FIG. 5 is asecond perspective view showing the preliminary-inspection-sample-makingstep according to the embodiment of the present invention; FIG. 6 is aperspective view of a preliminary inspection sample associated with theembodiment of the present invention; FIG. 7 is a plan view showing afirst cutting step according to the embodiment of the present invention;FIG. 8 is a front view showing the first cutting step according to theembodiment of the present invention; FIG. 9 is a front view showing acleaning step according to the embodiment of the present invention; FIG.10 is a plan view showing the preliminary inspection sample associatedwith the embodiment of the present invention as viewed after the firstcutting step and the cleaning step; FIG. 11 is a plan view showing therelationship between the preliminary inspection sample and a cuttingdevice according to the embodiment of the present invention; FIG. 12 isa front view showing the relationship between the preliminary inspectionsample and the cutting device according to the embodiment of the presentinvention; FIG. 13 is a first front view showing a second cutting stepaccording to the embodiment of the present invention; FIG. 14 is asecond front view showing the second cutting step according to theembodiment of the present invention; FIG. 15 is a perspective viewshowing an inspection sample associated with the embodiment of thepresent invention; and FIG. 16 is a front view showing a drying stepaccording to the embodiment of the present invention.

In FIG. 3, reference numeral 10 denotes a packaging container; referencenumeral 12 denotes an inspection sample; reference numeral 30 denotes aninspection sample making apparatus for making the inspection sample 12;reference numeral 31 denotes a seal condition inspection apparatus forinspecting seal portions of the inspection sample 12 for seal condition;reference numeral 51 denotes a conveyor, which serves as a conveyingdevice; and reference numeral 52 denotes a preliminary inspectionsample.

Reference numeral p1 denotes a first accumulation section, and referencenumeral p2 denotes a second accumulation section. The conveyor 51 isdisposed between the first and second accumulation sections p1 and p2.First to fourth stop positions Sp1 to Sp4 are set along the conveyor 51.When an object of conveyance, such as the packaging container 10, thepreliminary inspection sample 52, or the inspection sample 12, conveyedon the conveyor 51 reaches a predetermined stop position, the conveyor51 is caused to halt for a predetermined time. Thus, the conveyor 51 iscaused to run intermittently through activation of an unillustratedconveyor motor, such as a servomotor, which serves as a conveyor drivesection.

A first work station Sn1 for carrying out apreliminary-inspection-sample-making step, a second work station Sn2 forcarrying out a first cutting step and a cleaning step, a third workstation Sn3 for carrying out a second cutting step, and a fourth workstation Sn4 for carrying out a drying step are disposed on one side—inthe present embodiment on the left-hand side—with respect to the runningdirection of the conveyor 51, in correspondence with the first to fourthstop positions Sp1 to Sp4, respectively.

Unillustrated first and second moving mechanisms are disposed at thefirst to fourth stop positions Sp1 to Sp4 in order to move objects ofconveyance between the first to fourth stop positions Sp1 to Sp4 and thefirst to fourth work stations Sn1 to Sn4, respectively. Notably, in thepresent embodiment, the first moving mechanism is adapted tosimultaneously move objects of conveyance between the first and secondstop positions Sp1 and Sp2 and the first and second work stations Sn1and Sn2, respectively; and the second moving mechanism is adapted tosimultaneously move objects of conveyance between the third and fourthstop positions Sp3 and Sp4 and the third and fourth work stations Sn3and Sn4, respectively.

The first and second moving mechanisms include traversers supported insuch a manner as to be movable between the first to fourth stoppositions Sp1 to Sp4 and the first to fourth work stations Sn1 to Sn4,respectively; chains for moving the corresponding traversers; two vacuumpads disposed at the distal end of each of the traversers and serving asa first holding-power-generating member; and a vacuum pump or the likeserving as a vacuum source for generating a negative pressure within thevacuum pads. The traversers vacuum-chuck corresponding objects ofconveyance through generation of a vacuum pressure within the vacuumpads, and move the objects of conveyance between the first to fourthstop positions Sp1 to Sp4 and the first to fourth work stations Sn1 toSn4, respectively.

In the thus-configured inspection sample making apparatus 30, somepackaging containers 10 are selected for inspection purpose from amongthe packaging containers 10 ejected from the filling apparatus inaccordance with a predetermined rule and are accumulated in the firstaccumulation section p1 by means of an unillustrated chute, which servesas a predetermined accumulation device. Subsequently, a loading processmeans of an unillustrated control section performs a loading process tothereby activate an unillustrated pusher device. The pusher devicepushes out the bottom packaging container 10 from the chute, therebyplacing the packaging container 10 onto the conveyor 51. Next, aconveying process means of the control section performs a conveyingprocess to thereby activate the conveyor motor. Thus, the conveyor 51 iscaused to run, thereby conveying the packaging container 10.

When the packaging container 10 reaches the first stop position Sp1, theconveying process means causes the conveyor motor to stop, therebystopping the conveyor 51. Subsequently, a moving process means of thecontrol section performs a moving process to thereby activate the firstmoving mechanism. The first moving mechanism moves the packagingcontainer 10 from the first stop position Sp1 to the first work stationSn1. In the first work station Sn1, thepreliminary-inspection-sample-making step is carried out, whereby thepackaging container 10 is formed into a preliminary inspection sample52, which serves as a primary, preliminary inspection sample.

Thus, a preliminary-inspection-sample-making device 20 as shown in FIGS.4 and 5 is disposed in the first work station Sn1. Thepreliminary-inspection-sample-making device 20 includes first and secondunfolding devices 55 and 56 for peeling the top flaps 10 g and 10 h,which serve as a first fusion-bonded piece or a first lug, off the sidewalls 10 c and 10 d, respectively, of the packaging container 10; thirdand fourth unfolding devices 57 and 58 for peeling bottom flaps 10 i and10 j, which serve as a second fusion-bonded piece or a second lug, offthe bottom wall 10 f of the packaging container 10; an unillustratedfirst positioning mechanism for vertically and horizontally moving thefirst and second unfolding devices 55 and 56 so as to position the firstand second unfolding devices 55 and 56; and an unillustrated secondpositioning mechanism for vertically moving the third and fourthunfolding devices 57 and 58 so as to position the third and fourthunfolding devices 57 and 58.

Each of the first and second unfolding devices 55 and 56 includes amotor 61, such as a servomotor, which serves as an unfolding drivesection; a rod 62, which is connected to the output shaft of the motor61 and serves as an output member; and a peeling piece 63, which isconnected to the distal end of the rod 62 and is formed of a thin plateshaped like a lying squarish letter U. An insert portion 65 is formed atthe distal end (the lower end in FIG. 4) of the peeling piece 63. Eachof the third and fourth unfolding devices 57 and 58 includes the motor61, such as a servomotor, which serves as an unfolding drive section;the rod 62, which is connected to the output shaft of the motor 61 andserves as an output member; and a peeling piece 64, which is connectedto the distal end (the upper end in FIG. 5) of the rod 62 and is formedof a thin plate shaped like a letter L. An insert portion 65 is formedat the distal end of the peeling piece 64.

The thus-configured preliminary-inspection-sample-making device 20functions as follows. An unfolding process means of the control sectionperforms an unfolding process to thereby activate the first positioningmechanism. The first and second unfolding devices 55 and 56 are causedto lower in the direction of arrow A and then to move in the directionof arrow B, whereby the insert portions 65 are inserted between the topflap 10 g and the side wall 10 c and between the top flap 10 h and theside wall 10 d, respectively. Subsequently, the unfolding process meansactivates the motors 61, thereby rotating the peeling pieces 63 180° inthe direction of arrow C. As a result, the top flaps 10 g and 10 h arecaused to rotate 180° in the direction of arrow D, to thereby be peeledoff the side walls 10 c and 10 d, respectively.

Also, the unfolding process means activates the second positioningmechanism synchronously with the operation of the first and secondunfolding devices 55 and 56, whereby the third and fourth unfoldingdevices 57 and 58 are caused to rise in the direction of arrow E, tothereby insert the insert portions 65 between the bottom wall 10 f andthe bottom flaps 10 i and 10 j, respectively. Subsequently, theunfolding process means activates the motors 61, thereby rotating thepeeling pieces 64 180° in the direction of arrow F. As a result, thebottom flaps 10 i and 10 j are caused to rotate 180° in the direction ofarrow G, to thereby be peeled off the bottom wall 10 f.

Thus, in the first work station Sn1, the packaging container 10undergoes the above processes and is thus formed into the preliminaryinspection sample 52 as shown in FIG. 6. When the motors 61 areactivated, load current flowing through the coils of the motors 61 isdetected. On the basis of the detected load current, a rotation torqueof each of the peeling pieces 63 and 64 is calculated.

Subsequently, the moving process means activates the first movingmechanism, thereby moving the preliminary inspection sample 52 from thefirst work station Sn1 to the first stop position Sp1. Then, theconveying process means again activates the conveyor motor, therebycausing the conveyor 51 to resume running for conveying the preliminaryinspection sample 52.

When the preliminary inspection sample 52 reaches the second stopposition Sp2, the conveying process means causes the conveyor motor tostop, thereby stopping the conveyor 51. Subsequently, the moving processmeans activates the first moving mechanism to thereby move thepreliminary inspection sample 52 from the second stop position Sp2 tothe second work station Sn2.

In the second work station Sn2, the first cutting step and the cleaningstep are carried out, whereby the preliminary inspection sample 52 iscut and cleaned. Thus, as shown in FIGS. 7 to 9, the second work stationSn2 is equipped with a support table 80 for supporting the preliminaryinspection sample 52. First and second holders 71 and 72, which eachhave a shape of a letter L, are disposed on the support table 80 for thepurpose of holding the preliminary inspection sample 52. The first andsecond holders 71 and 72 are each supported in such a manner as to bepivotable on a predetermined point. Each of the first and second holders71 and 72 includes a press portion 73 adapted to press a predeterminedwall—in the present embodiment the front wall 10 a—of the preliminaryinspection sample 52; and a support portion 74 extending perpendicularlyto the press portion 73. The first and second holders 71 and 72 arepivotally moved between a working position shown in FIGS. 7 and 8 and aretreat position shown in FIG. 9. The first and second holders 71 and 72press the preliminary inspection sample 52 at the working position andrelease the preliminary inspection sample 52 at the retreat position.

The first and second holders 71 and 72 each have a slit 75 formedtherein in such a manner as to extend along the entire length of thepress portion 73 and to extend from the upper end of the support portion74 to a predetermined position—in the present embodiment an intermediateportion—of the support portion 74.

The second work station Sn2 is further equipped with a cutting-cleaningdevice 70. The cutting-cleaning device 70 includes a first cuttingdevice 90 for cutting open, at a predetermined position, the preliminaryinspection sample 52 held by the first and second holders 71 and 72; anda cleaning device 67 for cleaning the preliminary inspection sample 52that is cut open.

The first cutting device 90 includes a cutter 87, which serves as acutting tool; a support member 68 for supporting the cutter 87; and acutting air cylinder 69, which is attached to the support member 68 forreciprocatively moving the cutter 87 in the direction of arrow I andserves as a cutting drive section. The cutting air cylinder 69 includesa cylinder body 77; a piston 78, which is disposed within the cylinderbody 77 in such a manner as to be slidable in the direction of arrow H;and a piston rod 79, which extends frontward (leftward in FIGS. 7 to 9)from the piston 78 and whose front end (left end in FIGS. 7 to 9) isconnected to the support member 68. When the cutting air cylinder 69 isactivated to thereby move the cutter 87 forward (leftward in FIGS. 7 to9), the cutter 87 moves along the slit 75, thereby cutting apredetermined wall—in the present embodiment the front wall 10 a, aportion of the side wall 10 c, and a portion of the side wall 10 d—ofthe preliminary inspection sample 52 along a first cutting line L1,which is set beforehand on the preliminary inspection sample 52 in thelateral direction.

The cleaning device 67 includes a pressure plate 81, which covers thesubstantially entire preliminary inspection sample 52 and is adapted topress the cut preliminary inspection sample 52 flat to thereby eject aliquid food from the interior of the preliminary inspection sample 52,thus serving as a press member; nozzles 82, which are attached to thepressure plate 81 at predetermined positions—in the present embodimentat positions facing the side walls 10 c and 10 d of the preliminaryinspection sample 52—and are adapted to spray a cleaning liquid, such aswater, toward the preliminary inspection sample 52 and which serve as acleaning liquid supply section; and a cleaning air cylinder 83, which isattached to the pressure plate 81 in order to reciprocatively move thepressure plate 81 in the direction of arrow J and serves as a cleaningdrive section. The cleaning air cylinder 83 includes a cylinder body 84;a piston 85, which is disposed slidably within the cylinder body 84; anda piston rod 86, which extends frontward (downward in FIG. 9) from thepiston 85 and whose front end (lower end in FIG. 9) is connected to thepressure plate 81. When the cleaning air cylinder 83 is activated tothereby move the pressure plate 81 forward (downward in FIG. 9), thepressure plate 81 presses the preliminary inspection sample 52 via apredetermined wall—in the present embodiment the front wall 10 a—of thepreliminary inspection sample 52.

The thus-configured cutting-cleaning device 70 functions as follows.When the preliminary inspection sample 52 is moved from the second stopposition Sp2 to the second work station Sn2 and is then placed on thesupport table 80, a first cutting process means of the control sectionperforms a first cutting process. The first and second holders 71 and 72are brought to the working position. The cutting air cylinder 69 isactivated so as to move the cutter 87 forward, whereby the preliminaryinspection sample 52 is cut along the first cutting line L1.Subsequently, the cutting air cylinder 69 is activated so as to retreatthe cutter 87 (so as to move the cutter 87 rightward in FIGS. 7 to 9).Then, a cleaning process means of the control section performs acleaning process. The first and second holders 71 and 72 are brought tothe retreat position. The cleaning air cylinder 83 is activated so as tomove the pressure plate 81 forward, thereby pressing the preliminaryinspection sample 52 flat and ejecting a liquid food. A cleaning liquidis sprayed from the nozzles 82, thereby cleaning the preliminaryinspection sample 52 in such a manner as to remove the liquid food fromthe inner and outer surfaces of the preliminary inspection sample 52.

In the second work station Sn2, the preliminary inspection sample 52undergoes the above processes and is thus formed into a secondarypreliminary inspection sample, which is the flat preliminary inspectionsample 52 having a cut 88 as shown in FIG. 10. Notably, in FIG. 10,reference numerals L2 and L3 are second and third cutting lines that areset beforehand on the preliminary inspection sample 52 in thelongitudinal direction for the purpose of cutting the preliminaryinspection sample 52 in the second cutting step, which will be describedlater.

Subsequently, the moving process means activates the first movingmechanism to thereby move the preliminary inspection sample 52 from thesecond work station Sn2 to the second stop position Sp2.

As mentioned previously, at the timing of the preliminary inspectionsample 52 on the conveyor 51 reaching the second stop position Sp2, thenext packaging container 10 on the conveyor 51 reaches the first stopposition Sp1, which is located upstream of the second stop position Sp2.When the first moving mechanism is activated to thereby move thepreliminary inspection sample 52 from the second stop position Sp2 tothe second work station Sn2, the packaging container 10 is moved fromthe first stop position Sp1 to the first work station Sn1. When,subsequently to completion of the first cutting step and the cleaningstep in the second work station Sn2, the first moving mechanism isactivated to thereby move the preliminary inspection sample 52 from thesecond work station Sn2 to the second stop position Sp2, thepreliminary-inspection-sample-making step is completed, and thepreliminary inspection sample 52 is moved from the first work stationSn1 to the first stop position Sp1.

Subsequently, the conveying process means again activates the conveyormotor, thereby causing the conveyor 51 to resume running for conveyingthe preliminary inspection sample 52.

When the preliminary inspection sample 52 reaches the third stopposition Sp3, the conveying process means causes the conveyor motor tostop, thereby stopping the conveyor 51. Subsequently, the moving processmeans activates the second moving mechanism to thereby move thepreliminary inspection sample 52 from the third stop position Sp3 to thethird work station Sn3. In the third work station Sn3, the secondcutting step is carried out, whereby the preliminary inspection sample52 is cut into the inspection sample 12. For carrying out the secondcutting step, as shown in FIGS. 11 and 12, a second cutting device 91 isdisposed in the third work station Sn3. The second cutting device 91cuts the preliminary inspection sample 52 into a predetermined shape.The second cutting device 91 includes lower blades 92 and 93, which aredisposed in parallel with each other with a predetermined distancemaintained therebetween and support the preliminary inspection sample 52and which serves as a pair of first blades; fixing blocks 94 and 95,which are disposed above the lower blades 92 and 93 in parallel witheach other with a predetermined distance maintained therebetween and ina reciprocatively movable manner and which serve as apreliminary-inspection-sample-fixing member; upper blades 96 and 97,which are disposed outside the fixing blocks 94 and 95, respectively, inparallel with each other with a predetermined distance maintainedtherebetween and in a reciprocatively movable manner (in a verticallymovable manner in FIG. 12) and which serve as a pair of second blades;and an unillustrated cutting air cylinder, which is adapted toreciprocatively move the upper blades 96 and 97, thus serving as acutting drive section. The fixing blocks 94 and 95 move between afrontward limit position and a backward limit position. In the frontwardlimit position, which serves as a fixing position, the fixing blocks 94and 95 press the preliminary inspection sample 52 against the lowerblades 92 and 93 to thereby fix the preliminary inspection sample 52. Inthe backward limit position, which serves as a retreat position, thefixing blocks 94 and 95 are in a retreat condition. The upper blades 96and 97 move between a frontward limit position and a backward limitposition. In the frontward limit position, which serves as a cuttingposition, the upper blades 96 and 97 press the preliminary inspectionsample 52 against the lower blades 92 and 93 and cut the preliminaryinspection sample 52. In the backward limit position, which serves as aretreat position, the upper blades 96 and 97 are in a retreat condition.

The lower blades 92 and 93 each include an elongated primary portion 101and expanded secondary portions 102 and 103, which integrate with theprimary portion 101 at corresponding opposite ends of the primaryportion 101 via inclined surfaces q1 and q2, respectively. Assuming ashape corresponding to that of the lower blades 92 and 93, the upperblades 96 and 97 each include an elongated primary portion 104 andreduced secondary portions 105 and 106, which integrate with the primaryportion 104 at corresponding opposite ends of the primary portion 104via inclined surfaces q3 and q4, respectively.

When the upper blades 96 and 97 are caused to move forward (downward inFIGS. 12 to 14), a first edge e1, which is formed at the outside edge ofthe upper surface of each of the lower blades 92 and 93, is engaged witha second edge e2, which is formed at the inside edge of the lowersurface of each of the upper blades 96 and 97 in such a manner as tocorrespond to the first edge e1. The preliminary inspection sample 52 isthus cut along the second and third cutting lines L2 and L3, which areset in such a manner as to correspond to the first and second edges e1and e2.

The thus-configured second cutting device 91 functions as follows. Inthe initial state, the fixing blocks 94 and 95 and the upper blades 96and 97 are brought in their retreat positions. When the preliminaryinspection sample 52 is moved from the third stop position Sp3 to thethird work station Sn3 and is then placed on the lower blades 92 and 93,a second cutting process means of the control section performs a secondcutting process. As shown in FIG. 13, the fixing blocks 94 and 95 arecaused to advance in the direction of arrow K and to be brought to thefixing position, thereby pressing the preliminary inspection sample 52against the lower blades 92 and 93 so as to fix the preliminaryinspection sample 52. Subsequently, as shown in FIG. 14, the secondcutting process means causes the upper blades 96 and 97 to advance inthe direction of arrow L and to be brought to the cutting position,thereby causing the first and second edges e1 and e2 to engage with eachother. As a result, the preliminary inspection sample 52 is cut alongthe second and third cutting lines L2 and L3, whereby the inspectionsample 12 is made. Notably, reference numerals 108 and 109 denote cutpieces formed in association with cutting of the preliminary inspectionsample 52.

In the third work station Sn3, the preliminary inspection sample 52undergoes the above processes and is thus formed into the inspectionsample 12 as shown in FIG. 15.

The inspection sample 12 includes at least two plate-like portions. Theplate-like portions are fusion-bonded together at at least a singlefusion bond portion. In the present embodiment, the inspection sample 12includes a first plate-like portion 13, which includes the back wall 10b (FIG. 2), a portion of the top wall 10 e, and a portion of the bottomwall 10 f; a second plate-like portion 14, which includes a portion ofthe front wall 10 a and a portion of the top wall 10 e; a thirdplate-like portion 15, which includes a portion of the front wall 10 aand a portion of the bottom wall 10 f; a first fusion bond portion 16,which includes a portion of the lateral seal portion S2 and fusion-bondsthe first and second plate-like portions 13 and 14 together; and asecond fusion bond portion 17, which includes a portion of the lateralseal portion S2 and fusion-bonds the first and third plate-like portions13 and 15 together.

The first plate-like portion 13 includes a rectangular trunk portion 21,and expansion portions 22 and 23, which are formed in such a manner asto gradually expand from corresponding opposite ends of the trunkportion 21 toward the first and second fusion bond portions 16 and 17,respectively. The second plate-like portion 14 includes a trunk portion24, and an expansion portion 25, which is formed in such a manner as togradually expand from one end of the trunk portion 24 toward the firstfusion bond portion 16. The third plate-like portion 15 includes a trunkportion 26, and an expansion portion 27, which is formed in such amanner as to gradually expand from one end of the trunk portion 26toward the second fusion bond portion 17.

Subsequently, the moving process means activates the second movingmechanism, thereby moving the inspection sample 12 from the third workstation Sn3 to the third stop position Sp3. Next, the conveying processmeans again activates the conveyor motor, thereby causing the conveyor51 to resume running for conveying the inspection sample 12. When theinspection sample 12 reaches the fourth stop position Sp4, the conveyingprocess means causes the conveyor motor to stop, thereby stopping theconveyor 51. Subsequently, the moving process means activates the secondmoving mechanism to thereby move the inspection sample 12 from thefourth stop position Sp4 to the fourth work station Sn4.

In the fourth work station Sn4, the drying step is carried out, wherebythe inspection sample 12 is developed to an open condition and is thendried. Thus, as shown in FIG. 16, the fourth work station Sn4 isequipped with a support table 111; an opening mechanism 112 disposed onopposite sides of the support table 111; and a drying device 110, whichincludes a drier section 113 disposed above the inspection sample 12.The opening mechanism 112 brings the inspection sample 12 to an opencondition, and the drier section 113 dries the inspection sample 12 inan open condition.

The opening mechanism 112 includes two vacuum pads 115 and 116, whichare pivotably disposed on corresponding opposite sides of the supporttable 111 and serve as a second holding-power-generating member; and anunillustrated vacuum pump or the like serving as a vacuum source forgenerating a negative pressure within the vacuum pads 115 and 116. Theopening mechanism 112 functions as follows. A negative pressure isgenerated within the vacuum pads 115 and 116 so as to vacuum-chuck thesecond and third plate-like portions 14 and 15. While vacuum-chuckingthe second and third plate-like portions 14 and 15, the vacuum pads 115and 116 are rotated in the direction of arrow M, thereby opening thesecond and third plate-like portions 14 and 15; i.e., bringing theinspection sample 12 to an open condition.

The drier section 113 includes a manifold 121, which is disposed in sucha manner as to extend in the longitudinal direction of the inspectionsample 12; a plurality of nozzles—in the present embodiment threenozzles 122 to 124—disposed along the manifold 121; and an unillustratedhot-air-generating device, which supplies high-temperature air as dryinggas, thus serving as a drying gas source. High-temperature air generatedby the hot-air-generating device is supplied in the direction of arrowN; flows to the manifold 121 through a pipe line 125; and is dischargedfrom the nozzles 122 to 124 toward the inspection sample 12. As aresult, the inner surface of the inspection sample 12 is dried.

The thus-configured drying device 110 functions as follows. When theinspection sample 12 is moved from the fourth stop position Sp4 to thefourth work station Sn4 and is then placed on the support table 111, adrying process means of the control section performs a drying process.Specifically, the drying process means activates the opening mechanism112 to thereby bring the inspection sample 12 to an open condition.Also, the drying process means activates the drier section 113 tothereby discharge high-temperature air from the nozzles 122 to 124toward the inspection sample 12, thereby drying the inner surface of theinspection sample 12.

In the fourth work station Sn4, the inspection sample 12 undergoes theabove processes and is thus developed and dried.

Subsequently, the moving process means activates the second movingmechanism, thereby moving the inspection sample 12 from the fourth workstation Sn4 to the fourth stop position Sp4.

As mentioned previously, at the timing of the inspection sample 12 onthe conveyor 51 reaching the fourth stop position Sp4, the nextpreliminary inspection sample 52 on the conveyor 51 reaches the thirdstop position Sp3, which is located upstream of the fourth stop positionSp4 on the conveyor 51. When the second moving mechanism is activated tothereby move the inspection sample 12 from the fourth stop position Sp4to the fourth work station Sn4, the preliminary inspection sample 52 ismoved from the third stop position Sp3 to the third work station Sn3.When, subsequently to completion of the drying step in the fourth workstation Sn4, the second moving mechanism is activated to thereby movethe inspection sample 12 from the fourth work station Sn4 to the fourthstop position Sp4, the second cutting step is completed, and theinspection sample 12 is moved from the third work station Sn3 to thethird stop position Sp3.

Subsequently, the conveying process means again activates the conveyormotor, thereby causing the conveyor 51 to resume running for conveyingthe inspection sample 12 to the second accumulation section p2. In thesecond accumulation section p2, the sample 12 is accumulated.

The inspection samples 12 are thus made and accumulated in the secondaccumulation section p2. The accumulated inspection samples 12 are sentone by one to the seal condition inspection apparatus 31. The sealcondition inspection apparatus 31 includes an unillustrated inspectionmotor, which serves as an inspection drive section; and an unillustratedrotary-body unit, which is rotated intermittently every elapse of apredetermined time through activation of the inspection motor. Therotary-body unit includes a hub connected to an output shaft of theinspection motor, and a plurality of—in the present inventionsix—mandrels extending radially from the hub and arranged at equal pitchspacings.

Each of the mandrels has an inspection sample holder, which is locatedat the distal end of the mandrel for the purpose of holding theinspection sample 12 and, thus serving as an inspection sample supportportion. Each of the mandrels is caused to halt for a predetermined timeat six stations ST1 to ST6 arranged in the rotational direction of therotary-body unit.

The station ST1 is used as a loading-positioning section. The inspectionsample 12 is loaded into the station ST1 at predetermined timing and isset onto the mandrel. Thus, a conveyor 131, which serves as a conveyingdevice, is disposed in the station ST1. The sample 12 conveyed on theconveyor 131 is loaded into the station ST1.

The station ST2 is used as a first inspection section. In the stationST2, a first inspection for seal condition of a seal portion is carriedout. For this inspection, an unillustrated electrostatic-capacity-typeinspection equipment is disposed in opposition to the inspection sampleholder. The station ST3 is used as a second inspection section. In thestation ST3, a second inspection for seal condition is carried out. Forthis inspection, an unillustrated image-pickup-type inspection equipmentis disposed in opposition to the inspection sample holder. The stationST4 serves as a spare position for adjustment of timing.

The station ST5 is used as a third inspection section. In station ST5, athird inspection for seal condition is carried out. For this inspection,a discharge-type inspection equipment is disposed in opposition to theinspection sample holder. The station ST6 is used as a delivery sectionfor the inspection sample 12. In the station ST6, the inspection sample12 that has been inspected for seal condition is delivered.

As described above, according to the present embodiment, in the firstwork station Sn1, the preliminary inspection sample 52 is made by meansof the preliminary-inspection-sample-making device 20; and in the secondand third work stations Sn2 and Sn3, the preliminary inspection sample52 is cut into the inspection sample 12 by means of the first and secondcutting devices 90 and 91. Thus, an operator does not need to manuallymake an inspection sample. Therefore, not only is work for making aninspection sample simplified, but also cutting at a wrong position isavoided. As a result, the seal condition inspection apparatus 31 canreliably inspect seal condition.

The present invention is not limited to the above-described embodiment.Numerous modifications and variations of the present invention arepossible in light of the spirit of the present invention, and they arenot excluded from the scope of the present invention.

INDUSTRIAL APPLICABILITY

The present invention can be applied to an inspection sample makingapparatus for inspecting packaging containers for seal condition.

1. An inspection sample making apparatus comprising: (a)preliminary-inspection-sample-making means, including a peelinginstrument, for peeling a fusion-bonded portion of a packaging containeroff a wall of the packaging container so as to make a preliminaryinspection sample; and (b) cutting means for cutting the preliminaryinspection sample along a predetermined cutting line so as to make aninspection sample.
 2. An inspection sample making apparatus according toclaim 1, wherein the peeling instrument comprises an insert portion forinsertion between the fusion-bonded portion and the wall.
 3. Aninspection sample making apparatus according to claim 2, wherein thepeeling instrument is a thin plate.
 4. An inspection sample makingapparatus according to claim 1, wherein the cutting means comprises afirst cutting device for cutting the preliminary inspection sample alonga lateral first cutting line, and a second cutting device for cuttingthe preliminary inspection sample along longitudinal second and thirdcutting lines.
 5. An inspection sample making apparatus according toclaim 4, wherein the second cutting device comprises first and secondblades.
 6. An inspection sample making apparatus according to claim 4,wherein the first and second blades are lower blades which are paralleland are spaced apart to support the preliminary inspection sample alongthe second and third cutting lines, and further comprising third andfourth blades which are reciprocably driven and are arranged in parallelabove the first and second blades, respectively, for cutting thepreliminary inspection sample along the second and third cutting linesin cooperation with the first and second blades.
 7. An inspection samplemaking apparatus according to claim 4, wherein said first cutting devicecomprises a cutting blade and reciprocating drive means for reciprocablydriving said cutting blade across the first cutting line.
 8. Aninspection sample making apparatus according to claim 7, wherein thereciprocating drive means comprises a cylinder and a piston slidablymounted in said cylinder.
 9. An inspection sample making apparatusaccording to claim 1, further comprising a cleaning device for cleaningthe preliminary inspection sample.
 10. An inspection sample makingapparatus according to claim 9, wherein the cleaning device comprises apress member for ejecting a liquid food from the inside of thepreliminary inspection sample.
 11. An inspection sample making apparatusaccording to claim 10, wherein the cleaning device further comprisesliquid spray nozzles for spraying a cleaning liquid onto the preliminaryinspection sample.
 12. An inspection sample making apparatus accordingto claim 1, further comprising a drying device for drying the inspectionsample.
 13. An inspection sample making apparatus according to claim 12,further comprising: (a) an opening mechanism for opening the inspectionsample, wherein (b) the drying device dries the inspection sample in anopened condition.
 14. An inspection sample making apparatus according toclaim 1, wherein the cutting means makes an inspection sample comprisingat least two plate-like portions which are fusion-bonded together at afusion bond portion.
 15. An inspection sample making apparatus accordingto claim 1, wherein said preliminary-inspection-sample-making meansfurther includes rotary drive means for rotatably driving the peelinginstrument.